Battery cell assembly having improved thermal sensing capability

ABSTRACT

A battery cell assembly having a battery cell and a thin profile sensor is provided. The assembly includes a battery cell having a housing and first and second electrical terminals extending from the housing. The assembly further includes a thin profile sensor having a microprocessor and a sensing circuit. The sensing circuit is coupled directly to the housing. The sensing circuit generates a signal that is indicative of an operational parameter value of the battery cell. The microprocessor is programmed to determine the operational parameter value based on the signal from the sensing circuit. The assembly further includes a protective layer coupled to the thin profile sensor such that the sensor is disposed between the protective layer and the housing.

BACKGROUND

The inventor herein has recognized a need for a battery cell assemblythat utilizes a thin profile sensor coupled directly to a housing of abattery cell for determining operational parameter values associatedwith the battery cell.

SUMMARY

A battery cell assembly in accordance with an exemplary embodiment isprovided. The battery cell assembly includes a battery cell having ahousing and first and second electrical terminals extending from thehousing. The battery cell assembly further includes a thin profilesensor disposed directly on the housing. The thin profile sensor has amicroprocessor and a sensing circuit. The sensing circuit is coupleddirectly to the housing. The microprocessor and the sensing circuit areoperably coupled together. The sensing circuit is configured to generatea signal that is indicative of an operational parameter value of thebattery cell. The microprocessor is programmed to determine theoperational parameter value based on the signal from the sensingcircuit. The microprocessor is further programmed to store theoperational parameter value in a memory device. The battery cellassembly further includes a protective layer that is coupled to anddisposed over the thin profile sensor such that the thin profile sensoris disposed between the protective layer and the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of a battery system having a battery cell assemblyand a battery control module;

FIG. 2 is a schematic of a first side of the battery cell assembly ofFIG. 1 in accordance with an exemplary embodiment;

FIG. 3 is a schematic of a second side of the battery cell assembly ofFIG. 1;

FIG. 4 is a cross-sectional schematic of a portion of the battery cellassembly of FIG. 1 taken along lines 4-4;

FIG. 5 is a cross-sectional schematic of another portion of the batterycell assembly of FIG. 1 taken along lines 5-5;

FIG. 6 is an electrical schematic of a thin profile sensor utilized inthe battery cell assembly of FIG. 1 having a sensing circuit, areference voltage circuit, a data transmitting circuit, a data receivingcircuit, and a heat generating circuit; and

FIGS. 7 and 8 are flowcharts of a method for determining an operationalparameter associated with the battery cell assembly, and for controllingthe operational parameter value utilizing the thin profile sensor ofFIG. 6.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, a battery system 10 having a battery cellassembly 20 in accordance with an exemplary embodiment, and a batterycontrol module 30 is provided.

Referring to FIGS. 1, 3, 5 and 7, the battery cell assembly 20 includesa battery cell 40, a thin profile sensor 50, and protective layers 52,54. An advantage of the battery cell assembly 20 is that the thinprofile sensor 50 is coupled to and disposed directly to a housing 60 ofthe battery 40 and determines an operational parameter value associatedwith the battery cell 40, and controls an operational parameter of thebattery cell 40 based on the operational parameter value. In particular,in an exemplary embodiment, the thin profile sensor 50 determines atemperature value associated with the battery cell 40 utilizing asensing circuit 100, and controls a heat generating circuit 108 toadjust a temperature level of the battery cell 40 based on thetemperature value.

For purposes of understanding, the term “trace” means a thinelectrically conductive member herein.

Referring to FIGS. 1-5, the battery cell 40 has a housing 60 andelectrical terminals 62, 64 extending from the housing 60. The batterycell 40 further includes a plastic layer 70, an anode layer 72, aseparator layer 74, a cathode layer 76, and a plastic layer 78. Theanode layer 72 is coupled between and to the plastic layer 70 and theseparator layer 74. The anode layer 72 is electrically coupled to theelectrical terminal 62. The cathode layer 76 is coupled between and tothe separator layer 74 and the plastic layer 78. The cathode layer 76 iselectrically coupled to the electrical terminal 64. The anode layer 72and the cathode layer 76 generate a voltage between the electricalterminals 62, 64. In an exemplary embodiment, the battery cell 40 is alithium-ion pouch-type battery cell. Further, in the exemplaryembodiment, the housing 60 (shown in FIG. 3) is substantiallyrectangular-shaped and has an outer surface 66 (shown in FIG. 4). In analternative embodiment, the battery cell 40 could be another type ofbattery cell such as a nickel-metal-hydride battery cell, or anickel-cadmium battery cell for example. Further, in an alternativeembodiment, the housing 60 of the battery cell 40 could have anothershape such as a cylindrical shape for example. Still further, in analternative embodiment, the battery cell 40 could be replaced withanother type of energy storage cell. For example, the battery cell 40could be replaced with an ultracapacitor with first and secondelectrical terminals extending therefrom, or replaced with asupercapacitor with first and second electrical terminals extendingtherefrom.

Referring to FIGS. 4-6, the thin profile sensor 50 is configured todetermine an operational parameter value of the battery cell 40 and tocontrol an operational parameter of the battery cell 40 based on theoperational parameter value. For example, in an exemplary embodiment,the thin profile sensor 50 utilizes the sensing circuit 100 to determinea temperature value of the battery cell 40, and controls the heatgenerating circuit 108 to adjust a temperature level of the battery cell40 based on the temperature value.

The thin profile sensor 50 includes a microprocessor 90, a sensingcircuit 100, a reference voltage circuit 102, a data receiving circuit104, a data transmitting circuit 106, a heat generating circuit 108, andleads 110, 112. The microprocessor 90 is operably and electricallycoupled to the sensing circuit 100, the data receiving circuit 104, thedata transmitting circuit 106, and the heat generating circuit 108. Inan exemplary embodiment, the sensing circuit 100 and the heat generatingcircuit 108 are coupled to and disposed directly on the outer surface 66(shown in FIG. 4) of the housing 60. Further, at least a portion of thedata receiving circuit 104 and the data transmitting circuit 106 arecoupled to and disposed directly on the outer surface 66 of the housing60.

Referring to FIGS. 1, 2, 5 and 6, the microprocessor 90 is programmed todetermine an operational parameter value (e.g., temperature value) ofthe battery cell 40 and to control an operational parameter (e.g.,temperature level) of the battery cell 40 based on the operationalparameter value, as will be described in greater detail below. Themicroprocessor 90 includes a memory device 140, an analog-to-digitalconverter 142 having input-output (I/O) ports 150, 152, 154, 156, 158,160, 162, and an oscillator 170. The microprocessor 90 is electricallycoupled to the electrical terminals 62, 64 of the battery cell 40 viathe leads 110, 112. The electrical terminals 62, 64 are configured tosupply an operational voltage to the microprocessor 90. In an exemplaryembodiment, the microprocessor 90 is coupled to and disposed directly ona circuit board 119 (shown in FIG. 5), and the circuit board 119 iscoupled to and between the protective layer 52 and the plastic layer 70.In an alternative embodiment, the microprocessor 90 is coupled to anddisposed directly on the outer surface 66 of the housing 60 of thebattery cell 40 utilizing an adhesive or another attachment means. Inthis alternative embodiment, the circuit board 119 can be removed fromthe battery cell assembly 20. The microprocessor 90 utilizes softwareinstructions and/or data stored in the memory device 140 to implement atleast part of the tasks described herein with respect to themicroprocessor 90.

The sensing circuit 100 is configured to generate a signal that isindicative of an operational parameter value (e.g., temperature value)of the battery cell 40. In the illustrated embodiment, the sensingcircuit 100 is coupled to and disposed directly on the outer surface 66of the housing 60. Of course, in an alternative embodiment, at leastsome of the components of the sensing circuit 100 could be coupled toand disposed directly on the circuit board 119 (shown in FIG. 5) whichis further coupled to the housing 60. The sensing circuit 100 includes atransistor 190, resistors 194, 198, 202, 206, a resistive trace 210, andnodes 218, 222, 226. The resistive trace 210 has a resistance level thatvaries based on a temperature level of the battery cell 40.

Referring to FIG. 6, the transistor 190 includes a base B1, an emitterE1, and a collector C1. The emitter E1 is electrically coupled to a node218 which is further electrically coupled to an operational voltage on apositive electrical terminal of the battery cell 40. The node 218 isfurther electrically coupled to the I/O port 150 of the microprocessor90. The base B1 is electrically coupled to a node 222. The resistor 194is electrically coupled between the node 222 and the node 218. Further,the resistor 198 is electrically coupled between the node 222 and theI/O port 152. The resistor 202 is electrically coupled between thecollector C1 and the node 226. Further, the resistive trace 210 iselectrically coupled between the node 226 and a negative electricalterminal of the battery cell 40. Thus, the resistor 202 is electricallycoupled in series with the resistive trace 210, and the electrical node226 is electrically coupled therebetween. The resistor 202 is furtherelectrically coupled to an operational voltage when the transistor 190is turned on. The resistor 206 is electrically coupled between the node226 and the I/O port 154.

Referring to FIGS. 1 and 6, the resistive trace 210 has a resistancelevel that varies based on a temperature level of the battery cell 40,and is used by the microprocessor 90 to determine the temperature levelof the battery cell 40. In an exemplary embodiment, the resistive trace210 is coupled to and disposed directly on the outer surface 66 (shownin FIG. 4) of the housing 60. The resistive trace 210 includes resistivetrace portions 340, 342, 344, 346, 348, 350, 352, 354, 356, 358, 360,362, 364, 366 which are electrically coupled in series to one another.As shown, the resistive traces 342, 346, 350, 354, 358, 362 are spacedapart from one another and extend substantially parallel to one anotherlongitudinally along the first side 130 of the flexible plastic sheet80. In an exemplary embodiment, the resistive trace 210 has a thicknessin a range of 0.33-1.0 millimeters. Of course, in an alternativeembodiment, the resistive trace 210 could have a thickness greater than1.0 millimeter. In an exemplary embodiment, the resistive trace 210 isprinted on the outer surface 66 of the housing 60 and is constructed ofat least one of graphite, nickel, tin, silver, copper, or an alloy of atleast two of the foregoing materials.

In an alternative embodiment, the resistive trace 210 could have adifferent configuration on the housing 60. For example, the resistivetrace 210 could comprise a first plurality of trace portions that extendparallel to one another that are coupled together at end regions thereofwith one or more trace portions disposed substantially perpendicular tothe first plurality of trace portions to provide desired temperaturesensing coverage of the battery cell 40. Further, for example, theresistive trace 210 could comprise another combination of parallelextending trace portions coupled to one or more series trace portions toprovide desired temperature sensing coverage of the battery cell 40.

Since the resistive trace 210 has a resistance that varies based on atemperature of the battery cell 40, when the transistor 190 is turnedon, a voltage at the node 226 is indicative of a temperature level ofthe battery cell 40. Still further, a voltage applied to the I/O port154 is further indicative of a temperature level of the battery cell 40.

To determine a temperature level of the battery cell 40, themicroprocessor 90 is programmed to output a low logic level voltage onthe I/O port 152 to turn on the transistor 190. When the transistor 190is turned on, the microprocessor 90 is programmed to measure the voltage(temp_sense) on the resistor 206 at the I/O port 154. The microprocessor90 is further programmed to determine a temperature value representingthe temperature level of the battery cell 40 based on the voltage(temp_sense). In an exemplary embodiment, the microprocessor 90 utilizesa lookup table stored in the memory device 140 that has a plurality ofvoltage values (corresponding to voltage levels at the I/O port 154) anda plurality of associated temperature levels of the battery cell 40. Themicroprocessor 90 utilizes a measured voltage level to access anassociated temperature value in the lookup table, which corresponds to atemperature level of the battery cell 40.

The microprocessor 90 is further programmed to measure a voltage on theI/O port 150 to determine either a V_(open) or a V_(load) voltage of thebattery cell 40. In particular, the microprocessor 90 measures a voltageon the I/O port 150 when the transistor 300 is turned off whichcorresponds to the V_(open) voltage level of the battery cell 40.Alternately, the microprocessor measures a voltage on the I/O port 151the transistor 300 is turned on, which corresponds to the V_(load)voltage level of the battery cell 40.

The reference voltage circuit 102 is provided to input a referencevoltage to the I/O port 156 of the microprocessor 90. In the illustratedembodiment, the reference voltage circuit 102 is coupled to and disposeddirectly on the circuit board 119 (shown in FIG. 1). Of course, in analternative embodiment, at least some of the components of the referencevoltage circuit 102 could be coupled to and disposed directly on theouter surface 66 of the housing 60. The reference voltage circuit 102includes a resistor 230, a diode 232, and a node 234. The resistor 230is electrically coupled between an operational voltage and the node 234.The diode 232 is electrically coupled between the node 234 and anegative electrical terminal of the battery cell 40. The node 234 isfurther electrically coupled to the I/O port 156.

Referring to FIGS. 1 and 6, the data receiving circuit 104 is providedto allow the thin profile sensor 50 to receive data from the batterycontrol module 30. In the illustrated embodiment, at least some of thecomponents of the data receiving circuit 104 are coupled to and disposeddirectly on the circuit board 119 (shown in FIG. 1). Of course, in analternative embodiment, at least some of the components of the datareceiving circuit 104 could be coupled to and disposed directly on theouter surface 66 of the housing 60. The data receiving circuit 104includes an infrared receiving transistor 242, a resistor 244, a voltagebuffer 248, and the node 252. The transistor 242 includes a base B2, acollector C2, and an emitter E2. The collector C2 is electricallycoupled to a positive voltage terminal of the battery cell 40. Theemitter E2 is electrically coupled to a node 252 which is furthercoupled to the resistor 244. The resistor 244 is electrically coupledbetween the node 252 and a negative electrical terminal of the batterycell 40. The voltage buffer 248 is electrically coupled between the node252 and the I/O port 158 of the microprocessor 90. When the base B2receives infrared light having a threshold light level, the transistor242 turns on and supplies a voltage through the voltage buffer 248 tothe I/O port 158. Accordingly, when the infrared light has a binarymessage contained therein, the transistor 242 iteratively turns on andoff to supply a binary voltage message through the voltage buffer 248 tothe I/O port 158.

The data receiving circuit 104 is configured to receive a signal havinga binary message therein corresponding to a threshold operationalparameter value associated with the battery cell 40. For example, in anexemplary embodiment, the signal corresponds to an infrared lightsignal. Further, in an exemplary embodiment, the threshold operationalparameter value corresponds to at least one threshold temperature valueof the battery cell 40. Of course, in an alternative embodiment, thedata receiving circuit 104 could have a radio frequency (RF) receiveroperably coupled to the I/O port 158, and the received signal having thebinary message could correspond to an RF signal. Further, in analternative embodiment, the threshold operational parameter value couldcorrespond to another threshold parameter value associated with thebattery cell 40.

After receiving the signal with the binary message therein, the datareceiving circuit 104 is further configured to output a voltage signalhaving the binary message in response to the received signal. The binarymessage represents the threshold operational parameter value of thebattery cell 40, and is received by the microprocessor 90. In anexemplary embodiment, the binary message has a threshold operationalparameter value corresponding to at least one threshold temperaturevalue of the battery cell 40.

The data transmitting circuit 106 is provided to allow the thin profilesensor 50 to transmit data to the battery control module 30. Inparticular, the microprocessor 90 is programmed to generate a controlsignal to induce the data transmitting circuit 106 to transmit a signalhaving a first binary message therein representing a measuredoperational parameter value of the battery cell 40. In the illustratedembodiment, at least some of the components of the data transmittingcircuit 106 are coupled to and disposed directly on the circuit board119 (shown in FIG. 1). Of course, in an alternative embodiment, at leastsome of the components of the data transmitting circuit 106 could becoupled to and disposed directly on the outer surface 66 of the housing60. The data transmitting circuit 106 includes an infrared transmittingdiode 258, the transistor 260, resistors 264, 268, 272, diodes 276, 280,and a node 284.

The transistor 260 includes a base B3, a collector C3, and an emitterE3. The infrared transmitting diode 258 is electrically coupled betweenthe collector C3 and the positive electrical terminal of the batterycell 40. The resistor 264 is electrically coupled between the emitter E3and a negative electrical terminal of the battery cell 40. The resistor268 is electrically coupled between the base B3 and a negativeelectrical terminal of the battery cell 40. The base B3 is furtherelectrically coupled to a node 284. The diodes 276, 280 electricallycoupled in series between the node 284 and a negative electricalterminal of the battery cell 40. The resistor 272 is electricallycoupled between the node 284 and the I/O port 160 of the microprocessor90.

When the microprocessor 90 directs the I/O port 160 to output a highlogic level voltage, the transistor 260 turns on and the infraredtransmitting diode 258 emits infrared light. Accordingly, when themicroprocessor 90 desires to output a signal having a binary messagetherein corresponding to a measured operational parameter value of thebattery cell 40, the microprocessor 90 controls the voltage output bythe I/O port 160 to generate the infrared light signal having the binarymessage therein. In an exemplary embodiment, the binary message has ameasured operational parameter value corresponding to a measuredtemperature value of the battery cell 40.

Referring to FIGS. 1, 2 and 6, the heat generating circuit 108 isprovided to increase a temperature level of the battery cell 40 when atemperature level of the battery cell 40 is less than a thresholdtemperature level. In the illustrated embodiment, at least some of thecomponents of the heat generating circuit 108 are coupled directly tothe outer surface 66 (shown in FIG. 4) of the housing 60. Of course, inan alternative embodiment, at least some of the components of the heatgenerating circuit 108 could be disposed on the circuit board 119 (shownin FIG. 4) which is further coupled to the housing 60. The heatgenerating circuit 108 includes a transistor 300, a heating elementtrace 302, resistors 304, 308, 312, diodes 316, 320, nodes 324, 328, anda sense line 329.

The transistor 300 includes a base B4, a collector C4, and an emitterE4. The heating element trace 302 is electrically coupled between thecollector C4 and the positive electrical terminal of the battery cell40. The resistor 304 is electrically coupled between the emitter E4 anda negative electrical terminal of the battery cell 40. The sense line329 is electrically coupled between the emitter E4 and the I/O port 164of the microprocessor 90. The base B4 is electrically coupled to a node328. The diodes 316, 320 are electrically coupled in series between thenode 328 and a negative electrical terminal of the battery cell 40. Theresistor 312 is electrically coupled between the node 328 and the I/Oport 162 of the microprocessor 90.

The heating element trace 302 is configured to generate heat when avoltage is applied across the heating element trace 302. In theillustrated embodiment, the heating element trace 302 is a substantiallyserpentine-shaped heating element trace coupled to and disposed directlyon the flexible plastic sheet 80. Further, the heating element trace 302includes heating element trace portions 400, 402, 404, 406, 408, 410,412, 414, 416, 418, 420, 422, 424 coupled in series with one another.Further, in the exemplary embodiment, the heating element trace 302 isprinted on the outer surface 66 of the housing 60 and is constructed ofat least one of graphite, nickel, tin, silver, copper, or an alloy of atleast two of the foregoing materials. In an alternative embodiment, theheating element trace 302 could have a different configuration on theflexible plastic sheet 80. For example, the heating element trace 302could comprise a first plurality of heating element trace portions thatextend parallel to one another that are coupled together at end regionsthereof with one or more heating element trace portions disposedsubstantially perpendicular to the first plurality of heating elementtrace portions to provide desired heating coverage of the battery cell40. Further, for example, the heating element trace 302 could compriseanother combination of parallel extending heating element trace portionscoupled to one or more series heating element trace portions to providedesired heating coverage of the battery cell 40.

During operation, the microprocessor 90 is programmed to generate acontrol voltage to induce the transistor 300 of the heat generatingcircuit 108 to supply electrical current to the heating element trace302 to generate heat if the temperature value of the battery cell 40 isless than a first threshold temperature level. Further, themicroprocessor 90 is programmed to stop generating the control voltageto induce the transistor 300 of the heat generating circuit 108 to stopsupplying the electrical current to the heating element trace 302 toinduce the heating element trace 302 to stop generating heat if thetemperature value of the battery cell 40 is greater than a secondthreshold temperature value.

The microprocessor 90 is further programmed to determine an I_(load)current value by measuring a voltage at the node 324 when the transistor300 is turned on. The microprocessor 90 calculates the I_(load) currentvalue utilizing the following equation: I_(load)=voltage at node324/known resistance value of resistor 304.

Referring to FIG. 4, the protective layer 52 is coupled to and disposedover the thin profile sensor 50 such that the thin profile sensor 50 isdisposed between the protective layer 52 and the plastic layer 70 of thehousing 60. In an exemplary embodiment, the protective layer 52 isconstructed of a thin plastic layer. Further, in the exemplaryembodiment, the protective layer 52 is a substantially transparentplastic layer.

The protective layer 54 is coupled to and disposed over a side of theplastic layer 78 of the housing 60. In an exemplary embodiment, theprotective layer 54 is constructed of a thin plastic layer. Further, inthe exemplary embodiment, the protective layer 54 is a substantiallytransparent plastic layer.

Referring to FIGS. 1 and 6-8, a flowchart of a method for determining anoperational parameter value associated with a battery cell 40 and forcontrolling an operational parameter of the battery cell 40 based on theoperational parameter value will now be described.

At step 502, an operator provides the battery cell assembly 20 havingthe battery cell 40, the thin profile sensor 50, and the protectivelayers 52, 54. The battery cell 40 has a housing 60 and first and secondelectrical terminals 62, 64 extending from the housing 60. Theprotective layer 52 is coupled to and disposed over the thin profilesensor 50 such that the thin profile sensor 50 is disposed between theprotective layer 52 and the housing 60. The thin profile sensor 50 hasthe microprocessor 90, the sensing circuit 100, the heating generatingcircuit 108, the data transmitting circuit 106, and the data receivingcircuit 104. The microprocessor 90 is operably and electrically coupledto the sensing circuit 100, the heating generating circuit 108, the datatransmitting circuit 106, and the data receiving circuit 104. Thesensing circuit 100 and the heating generating circuit 108 are coupleddirectly to the housing 60. The sensing circuit 100 has a resistivetrace 210. The resistive trace 210 has a resistance level that variesbased on a temperature level of the battery cell 40. After step 502, themethod advances to step 504.

At step 504, the external battery control module 30 transmits a signalhaving a first binary message with: (i) a battery cell identifier value,(ii) a first temperature threshold value, and (iii) a second temperaturethreshold value. After step 504, the method advances to step 506.

At step 506, the data receiving circuit 104 receives the signal from theexternal battery control module 30 having the first binary message, andgenerates a signal having the battery cell identifier value and thefirst and second temperature threshold values that is received by themicroprocessor 90. After step 506, the method advances to step 508.

At step 508, the microprocessor 90 makes a determination as to whetherthe battery cell identifier value equals a stored battery cellidentifier value associated with the battery cell 40. The stored batterycell identifier value is stored in the memory device 140 prior to step508. If the value of step 508 equals “yes”, the method advances to step510. Otherwise, the method advances to step 512.

At step 510, the microprocessor 90 stores the first temperaturethreshold value and the second temperature threshold value in the memorydevice 140. After step 510, the method advances to step 520.

Referring again to step 508, if the value of step 508 equals “no”, themethod advances to step 512. At step 512, the microprocessor 90retrieves a first temperature threshold value and a second temperaturethreshold value that were previously stored in the memory device 140.After step 512, the method advances to step 520.

At step 520, the sensing circuit 100 generates a first voltage that isindicative of a temperature value of the battery cell 40. Thetemperature value indicates a temperature level of the battery cell 40.After step 520, the method advances to step 522.

At step 522, the microprocessor 90 determines the temperature value ofthe battery cell 40 based on the first voltage from the sensing circuit100. In particular, in an exemplary embodiment, the microprocessor 90accesses a lookup table stored in the memory device 140 that associatesa plurality of temperature values of the battery cell 40 with aplurality of the voltages from the sensing circuit 100, to select atemperature value utilizing the first voltage as an index to the lookuptable. After step 522, the method advances to step 524.

At step 524, the microprocessor 90 stores the temperature value in thememory device 140. After step 524, the method advances to step 526.

At step 526, the microprocessor 90 generates a control signal to inducethe data transmitting circuit 106 to transmit a signal having a secondbinary message with: (i) the battery cell identifier value, and (ii) thetemperature value of the battery cell 40. After step 526, the methodadvances to step 528.

At step 528, the external battery control module 30 receives the signalfrom the data transmitting circuit 106 having the second binary message.

At step 530, the microprocessor makes a determination as to whether thetemperature value is less than the first threshold temperature value. Ifthe value of step 530 equals “yes”, the method advances to step 532.Otherwise, the method advances to step 534.

At step 532, the microprocessor 90 generates a control voltage to inducethe heat generating circuit 108 to supply electrical current to theheating element trace 302 to generate heat to increase a temperaturelevel of the battery cell 40. After step 532, the method advances tostep 534.

At step 534, the microprocessor 90 makes a determination as to whetherthe temperature value is greater than a second threshold temperaturevalue. The second threshold temperature value is greater than the firstthreshold temperature value. If the value of step 534 equals “yes”, themethod advances to step 536. Otherwise, the method returns to step 520.

At step 536, the microprocessor 90 stops generating the control voltageto induce the heat generating circuit 108 to stop supplying theelectrical current to the heating element trace 302 to induce theheating element trace 302 to stop generating heat. After step 536, themethod returns to step 520.

The above-described method can be at least partially embodied in theform of one or more computer readable media having computer-executableinstructions for practicing the methods. The computer-readable media cancomprise one or more of the following: hard drives, RAM, ROM, flashmemory, and other computer-readable media known to those skilled in theart; wherein, when the computer-executable instructions are loaded intoand executed by one or more microprocessors, the one or moremicroprocessors become an apparatus for practicing the methods.

The battery cell assembly provides a substantial advantage over otherassemblies. In particular, battery cell assembly provides a technicaleffect of utilizing a thin profile sensor coupled to an exterior surfaceof the battery cell to determine an operational parameter valueassociated with the battery cell, and to control an operationalparameter of the battery cell based on the operational parameter value.In particular, the thin profile sensor determines a temperature valueassociated with the battery cell utilizing a sensing circuit, andcontrols a heat generating circuit to adjust a temperature level of thebattery cell based on the temperature value.

While the claimed invention has been described in detail in connectionwith only a limited number of embodiments, it should be readilyunderstood that the invention is not limited to such disclosedembodiments. Rather, the claimed invention can be modified toincorporate any number of variations, alterations, substitutions orequivalent arrangements not heretofore described, but which arecommensurate with the spirit and scope of the invention. Additionally,while various embodiments of the claimed invention have been described,it is to be understood that aspects of the invention may include onlysome of the described embodiments. Accordingly, the claimed invention isnot to be seen as limited by the foregoing description.

What is claimed is:
 1. A battery cell assembly, comprising: a pouch-typebattery cell having a pouch-type housing and first and second electricalterminals extending from the pouch-type housing; a temperature sensorbeing disposed directly on an outer surface of the pouch-type housing ofthe pouch-type battery cell, the temperature sensor having amicroprocessor, a circuit board, a sensing circuit, a heat generatingcircuit, and a data transmitting circuit; the microprocessor beingcoupled directly to the circuit board, and the microprocessor furtherdirectly contacting an outer surface of the pouch-type housing of thepouch-type battery cell, the circuit board directly contacting aprotective layer such that the circuit board is disposed between theprotective layer and the microprocessor, the protective layer having aperiphery that is greater than a periphery of the circuit board, thesensing circuit having a resistive trace being coupled directly to andcontacting the outer surface of the pouch-type housing of the pouch-typebattery cell; the resistive trace having a resistance level that variesbased on a temperature level of the pouch-type battery cell, themicroprocessor and the sensing circuit being operably coupled together;the microprocessor being programmed to determine a temperature valuecorresponding to the temperature level of the pouch-type battery cellbased on a signal from the sensing circuit; the microprocessor beingfurther programmed to store the temperature value in a memory device;the heat generating circuit having a heating element trace beingdisposed and printed directly on the outer surface of the pouch-typehousing, the heating element trace being electrically coupled to themicroprocessor; the protective layer being further coupled to anddisposed over the temperature sensor such that the resistive trace isdisposed between the protective layer and the outer surface of thepouch-type housing of the pouch-type battery cell; and the datatransmitting circuit being coupled at least in part to the circuitboard, the microprocessor being further programmed to generate a controlsignal to induce the data transmitting circuit to transmit a firstsignal having a first binary message therein externally through air, thefirst binary message representing the temperature value of thepouch-type battery cell.
 2. The battery cell assembly of claim 1,wherein: the signal comprises a first voltage on the sensing circuit. 3.The battery cell assembly of claim 2, wherein the sensing circuitfurther includes first and second resistors, the first resistor beingcoupled in series with the resistive trace with an electrical nodetherebetween, the first resistor being further electrically coupled toan operational voltage, the second resistor being coupled between theelectrical node and the microprocessor, the microprocessor being furtherprogrammed to measure the first voltage on the second resistor, themicroprocessor being further programmed to determine the temperaturevalue representing the temperature level of the pouch-type battery cellbased on the first voltage.
 4. The battery cell assembly of claim 1,wherein the resistive trace has a thickness in a range of 0.33-1.0millimeters.
 5. The battery cell assembly of claim 1, wherein theresistive trace has at least first, second and third resistive traceportions spaced apart from one another and extending substantiallyparallel to one another, the first, second, and third resistive portionselectrically coupled in series to one another and extendinglongitudinally along the pouch-type housing of the pouch-type batterycell.
 6. The battery cell assembly of claim 1, wherein the resistivetrace is constructed of at least one of graphite, nickel, tin, silver,copper, or an alloy of at least two of the foregoing materials.
 7. Thebattery cell assembly of claim 1, wherein the heating element trace is asubstantially serpentine-shaped heating element trace.
 8. The batterycell assembly of claim 1, wherein the heating element trace isconstructed of at least one of graphite, nickel, tin, silver, copper, oran alloy of at least two of the foregoing materials.
 9. The battery cellassembly of claim 1, wherein the microprocessor is further programmed togenerate a control voltage to induce the heat generating circuit tosupply electrical current to the heating element trace to generate heatif the temperature value of the pouch-type battery cell is less than afirst threshold temperature level.
 10. The battery cell assembly ofclaim 9, wherein the microprocessor is further programmed to stopgenerating the control voltage to induce the heat generating circuit tostop supplying the electrical current to the heating element trace toinduce the heating element trace to stop generating heat if thetemperature value of the pouch-type battery cell is greater than orequal to a second threshold temperature value.
 11. The battery cellassembly of claim 1, wherein the microprocessor is electrically coupledto the first and second electrical terminals of the pouch-type batterycell, the first and second electrical terminals configured to supply anoperational voltage to the microprocessor.
 12. The battery cell assemblyof claim 1, wherein the first signal is a first infrared signal havingthe first binary message therein representing the temperature value ofthe pouch-type battery cell.
 13. The battery cell assembly of claim 12,wherein the temperature sensor further includes a data receiving circuitbeing coupled at least in part to the circuit board, the data receivingcircuit configured to receive a second infrared signal having a secondbinary message therein, and to output a voltage signal having the secondbinary message in response to the received second signal, the secondbinary message having an operational parameter threshold value and isreceived by the microprocessor.
 14. The battery cell assembly of claim13, wherein the operational parameter threshold value comprises atemperature threshold value of the pouch-type battery cell.
 15. Abattery cell assembly, comprising: a pouch-type battery cell having apouch-type housing and first and second electrical terminals extendingfrom the pouch-type housing; a temperature sensor being coupled to anouter surface of the pouch-type housing of the pouch-type battery cell,the temperature sensor having a microprocessor, a sensing circuit, and aheat generating circuit; the sensing circuit having a resistive tracebeing coupled directly to and contacting the outer surface of thepouch-type housing of the pouch-type battery cell; the resistive tracehaving a resistance level that varies based on a temperature level ofthe pouch-type battery cell, the microprocessor and the sensing circuitbeing operably coupled together, the sensing circuit generating a signalthat is indicative of the temperature level of the pouch-type batterycell; the heat generating circuit having a heating element trace beingdisposed and printed directly on the outer surface of the pouch-typehousing, the heating element trace being electrically coupled to themicroprocessor; a protective layer being coupled to and disposed overthe temperature sensor such that the resistive trace and the heatingelement trace are disposed between the protective layer and the outersurface of the pouch-type housing of the pouch-type battery cell; themicroprocessor being programmed to determine a temperature valuecorresponding to the temperature level of the pouch-type battery cellbased on the signal from the sensing circuit; the microprocessor beingfurther programmed to store the temperature value in a memory device;and the microprocessor being further programmed to generate a controlsignal to induce the data transmitting circuit to transmit a firstinfrared signal having a first binary message therein, the first binarymessage representing the temperature value of the pouch-type batterycell.
 16. The battery cell assembly of claim 15, wherein themicroprocessor is further programmed to generate a control voltage toinduce the heat generating circuit to supply electrical current to theheating element trace to generate heat if the temperature value of thepouch-type battery cell is less than a first threshold temperaturelevel; and the microprocessor is further programmed to stop generatingthe control voltage to induce the heat generating circuit to stopsupplying the electrical current to the heating element trace to inducethe heating element trace to stop generating heat if the temperaturevalue of the pouch-type battery cell is greater than or equal to asecond threshold temperature value.
 17. The battery cell assembly ofclaim 15, wherein the microprocessor being coupled directly on the outersurface of the pouch-type housing of the pouch-type battery cellutilizing an adhesive.
 18. The battery cell assembly of claim 15,wherein the data transmitting circuit being coupled to and disposeddirectly on the outer surface of the pouch-type housing.